Sigtronics 200 S Installation Instructions
Sigtronics Sport 200 S Installation Instructions
INTRODUCTION
ATTENTION INSTALLER: To assure a trouble free installation,
please read the entire instructions through once before
beginning.
Sport 200 S SYSTEM SPECIFICATIONS
CONFIGURATION – The Sigtronics Sport 200 S Intercom system is
specifically designed for permanent, panel mounted installation in
aircraft. The Sport 200 S provides voice activated (VOX) intercom, a
Push-to-intercom mode for applications where voice activated ( VOX)
intercom operation is not desired, and music input for two headset
positions in a small single chassis unit.
STEREO MUSIC INPUT – Music input accepts standard portable music
headphone or line level outputs. Automobile Speaker level outputs can
be adapted for use with Sport 200 S systems.
COMPATIBILITY – Sigtronics Sport 200 S intercoms have been
designed to operate with all standard general aviation aircraft radios
and headsets.
SIZE: Panel 1” x 2.5”. Chassis - 1” high x 2.5” wide x 4” deep. Can be
mounted either horizontally or vertically in the aircraft panel.
WEIGHT: 5.5 ounces (Sport 200 S intercom unit with panel and knobs).
Jacks and wiring harness weigh 6.0 ounces
INPUT POWER: 11VDC through 32VDC. Maximum current drain 0.11
Amps
DISTORTION: Less than 1% total harmonic distortion.
WARRANTY: Sport 200 S intercoms are constructed of high quality
components and carry a five year parts and labor warranty.
HARDWARE SUPPLIED
Besides the intercom unit and instructions, each Sport 200 S system
comes with the following hardware:
Headphone Output Jacks - Accept standard 0.250” aircraft
stereo or monaural headphone plugs. .................................................2
Microphone Input Jacks - Accept standard 0.206” aircraft
microphone plugs. (U93 plug compatible jacks can be used in
place of the jacks provided – monaural installations only). ..........2
Mic Jack Insulating Washers, Flat ............................................................2
Mic Jack Insulating Washers, Shoulder .................................................2
Intercom Panel - lettered on both sides. ..............................................1
Intercom Control Knobs .............................................................................2
Mounting Screws 4-40 x 1/2 .....................................................................2
Drill Template - Adhesive backed hole size pattern for
drilling aircraft panel. ..................................................................................1
Intercom/Aircraft Interface Cable (4 feet long) .................................1
Headphone/Music Interface Cable (4 feet long) ...............................1
Stereo music input jack 3.5mm ...............................................................1
MUSIC MUTE OPTIONS
FACTORY DEFAULT - PARTIAL MUSIC MUTE DURING ICS - When
listening to music and someone speaks on the intercom the default
factory operation is to partially mute the music so you can hear the
conversation. The Sport 200 S intercoms have one additional option
that can be enabled if desired. This option is enabled with the intercom
removed from the aircraft.
FULL MUSIC MUTE DURING ICS OPTION - The music can be
completely muted during intercom conversations. To enable this
option, small jumper wires are installed on the solder side of the
circuit board.
CHASSIS INSTALLATION
UNIT PLACEMENT
The Sport 200 S unit has been designed to mount either horizontally
or vertically in your aircraft panel. The location selected for the Sport
200 S unit requires a minimum front panel area of 2 1/2” by 1”. Depth
required behind panel is 4” plus cable access.
CAUTION: Move the aircraft flight controls through the limits of travel
while observing the selected area and making sure that the rear of
the intercom and cable will not interfere with any aircraft control
components.
PANEL PREPARATION:
1. Position the adhesive drill template on the aircraft panel in the
selected area.
2. Center punch each hole at the cross lines. (Five holes are in a straight
line and equally spaced 0.4” apart)
3. Drill 1/8” pilot holes in all five places.
4. Enlarge holes to 1/4” and 3/8” per the template.
MOUNTING CHASSIS (See Figure 2)
1. Remove the knobs from the Volume and Squelch controls using a
0.050” Allen wrench. Remove the nut from the ON/OFF switch. NOTE:
DO NOT REMOVE the nuts from the Volume and Squelch controls.
Specialists in “SOUND” Management
178 East Arrow Highway, San Dimas, CA 91773 ( 909 ) 305-9399
SHOULDER
WASHER
FLAT
INSULATED
WASHER
FLAT
METAL
WASHER
NUT
AIRCRAFT
PANEL
RING
BARREL
TIP
RIGHT
LEFT
STEREO
+
-
+
-
+
-
+
-
R
C
R
C
C – 220 MFD, 25 VOLT CAPACITOR
R – 100 OHM, 5 WATT RESISTOR
NO CONNECTION
J2 (6) WHITE / VIOLET
J2 (4) WHITE / BROWN
J2 (5) BLACK
To Sport 200 S
Figure 2
DO NOT R EM OV E
THE SE N UT S
INT ER COM
AIRCRAFT
PANEL
INT ER COM
PANE L
SWI TCH
NUT
KNO B
4– 40 S CR EW S
KNO B
2. Insert the Sport 200 S unit from the rear of the aircraft panel with the
appropriate arrow on the unit chassis pointing upwards.
3. Install the printed Sport 200 S panel and lightly thread the two 4-40
screws through the holes in intercom panel. The nuts on the Volume
and Squelch controls will fit inside the 3/8” diameter holes.
4. Tighten the two screws and switch nut.
5. Install the knobs on the Volume (VOL) and Squelch (SQ) control shafts
and tighten the Allen screws.
MOUNTING HEADPHONE AND MICROPHONE JACKS (See Figure 3)
1. Locate the mounting areas. (One mic and one headphone jack required
for each headset). Again, make sure that the jacks will not interfere
with any aircraft control components. (Note that the jack contacts will
Figure 3
Microphone Jack
expand when a plug is inserted into the jack and must have clearance
to prevent shorting.)
2. Drill 3/8” diameter holes for headphone jacks and install.
3. Drill 1/2” diameter holes for the mic jacks and install with the insulating
washers supplied. (See Figure 3).
Note: If the aircraft already has pilot headset jacks, the location can be
used for intercom with the following changes. The mic jack must be
re-wired as follows:
1. Remove any existing wires from the tip, ring, and barrel connections.
2. Connect the intercom white/black wire to the ring terminal.
3. Connect one end of a ground wire to the barrel terminal of the mic jack
and connect the other end to Intercom Central ground Point “A”.
4. Install insulating washers as necessary if the barrel of the mic jack
is mounted in metal. For the headphone jack, replace the mono
headphone jack with the stereo headphone jack. Connect the green
wire (P2 pin 1) to the tip connection. Connect the white/green wire
(P2 pin 2) to the ring connection.
WIRING INSTRUCTIONS
Connections should be made as shown in Figure 4 and indicated in
Tables 1 & 2. Also read the following notes referenced in Tables 1 & 2.
If longer wire lengths are required, use a good quality multi stranded
hook-up wire - 22 gauge or larger. Although not necessary, shielded
audio wire can be used if desired.
1. The blue wire from Pin 3 must be connected to the aircraft radio
headphone output - NOT the speaker output. NOTE – If aircraft radio
volume heard in the headsets changes significantly when switching
the ON/OFF switch a minor modification to the installation will fix this.
Just install a small 1/4 watt resistor in line with the blue wire. Select a
value between 220 and 560 ohms for best results.
2. Connect all intercom mic jack grounds to a single aircraft chassis
ground point - Intercom Central ground Point “A” - as shown in Figure
4. (Use the black washers supplied to insulate the intercom mic jacks
from aircraft chassis ground). Note this intercom central grounding
point is used to eliminate any unwanted electrical noises, such as
alternator whine or strobe noise, from being induced into the intercom
system through the grounds. All intercom mic jack barrels must be
insulated from ground where they are mounted and connected back
to Intercom Central Ground Point “A” on their own individual ground
wire. Similarly, both intercom ground wires (J1 pin 4) and the pushto-transmit switch grounds must also be connected back to Intercom
Central Ground Point “A”. It is not necessary, however, to connect the
headphone jack barrels to Intercom Central Ground Point “A”. They can
either be grounded where they are mounted or some place nearby.
3. The red wire may be connected to either 12V (14V) or 24V (28V)
power source. No switching or adjustments are required to operate
from either source.
4. The Sport 200 S system provides a stereo music input. This music
input accepts portable music Headphone or Line level music sources.
The wiring diagram shows how to wire the Sport 200 S for use with a
portable stereo music source. A small stereo input jack is supplied for
this purpose. Connect the White/Brown, White/Violet, and Black wires
to one jack as shown in Figure 4. Identify the jack terminals using Figure
5. Drill a 1/4-inch hole for the jack
and mount on the aircraft panel.
Figure 5
To use, connect an adapter cable
between the music input jack and
the output of the portable stereo.
Suitable cables are available at
your local Stereo or electronics
store as well as from Sigtronics.
WHITE / VIOLET
TIP ( RIGHT )
WHITE / BROWN
RING ( LEFT )
Speaker level output car stereo
music sources can also be used
with the Sport 200 S system. A
Black
BARREL COMMON)
Floating Ground Adapter or a four
wire to three wire converter will have to be used between the Stereo
and the Sport 200 S music input. Figure 6 shows such an adapter and
how it is wired into the Sport 200 S.
5. The Sigtronics Sport 200 S system can be installed as shown for use
with Stereo headsets. Alternatively, monaural general aviation type
headsets can be used. To use monaural headsets follow the installation
instructions as normal except for the wiring of the stereo headphone
jacks. Use the stereo headphone jacks supplied with the Sigtronics
Sport 200 S but leave the “RING” connections open. Instead connect
both headphone wires to the “TIP” of the respective jacks. Connect
both the WHITE/GREEN and GREEN on to the TIP of the headphone
jack.
Figure 6
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AIRCRAFT PANEL
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